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We have a Lewmar Concept V3 Capitan/gypsy type windless that I have had apart for maintenance. It slides together without any hammer action. My guess is that you have some damage on the shaft that is interfering with the reassembly.
If you believe the friction is within the normal range and the key simply will not stay in place try some grease on the key to hold it while you wiggle things together. I have also seen where people use a pin punch on a key to dimple it in order to bet it to stay in place. I find that a bit extreme though...
Bruce
 
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